WO2014066718A1 - Compositions durcissables contenant des composés époxy à base de 1,3-dioxiranylcyclopentane et résines thermodurcissables préparées à partir de celles-ci - Google Patents

Compositions durcissables contenant des composés époxy à base de 1,3-dioxiranylcyclopentane et résines thermodurcissables préparées à partir de celles-ci Download PDF

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Publication number
WO2014066718A1
WO2014066718A1 PCT/US2013/066738 US2013066738W WO2014066718A1 WO 2014066718 A1 WO2014066718 A1 WO 2014066718A1 US 2013066738 W US2013066738 W US 2013066738W WO 2014066718 A1 WO2014066718 A1 WO 2014066718A1
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Prior art keywords
curable composition
compound
epoxide resin
resin compound
low viscosity
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PCT/US2013/066738
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English (en)
Inventor
Stephanie L. Potisek
Michael J. Mullins
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Dow Global Technologies Llc
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Application filed by Dow Global Technologies Llc filed Critical Dow Global Technologies Llc
Priority to KR1020157010411A priority Critical patent/KR20150079627A/ko
Priority to EP13786399.9A priority patent/EP2912028A1/fr
Priority to JP2015539825A priority patent/JP2015535308A/ja
Priority to CN201380054146.8A priority patent/CN104736528A/zh
Priority to US14/423,864 priority patent/US9382373B2/en
Publication of WO2014066718A1 publication Critical patent/WO2014066718A1/fr

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
    • C08G59/02—Polycondensates containing more than one epoxy group per molecule
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07D—HETEROCYCLIC COMPOUNDS
    • C07D301/00—Preparation of oxiranes
    • C07D301/02—Synthesis of the oxirane ring
    • C07D301/03—Synthesis of the oxirane ring by oxidation of unsaturated compounds, or of mixtures of unsaturated and saturated compounds
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07D—HETEROCYCLIC COMPOUNDS
    • C07D303/00—Compounds containing three-membered rings having one oxygen atom as the only ring hetero atom
    • C07D303/02—Compounds containing oxirane rings
    • C07D303/04—Compounds containing oxirane rings containing only hydrogen and carbon atoms in addition to the ring oxygen atoms
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
    • C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
    • C08G59/20—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the epoxy compounds used
    • C08G59/22—Di-epoxy compounds
    • C08G59/24—Di-epoxy compounds carbocyclic
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
    • C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
    • C08G59/20—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the epoxy compounds used
    • C08G59/32—Epoxy compounds containing three or more epoxy groups
    • C08G59/3218—Carbocyclic compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/04—Oxygen-containing compounds
    • C08K5/15—Heterocyclic compounds having oxygen in the ring
    • C08K5/151—Heterocyclic compounds having oxygen in the ring having one oxygen atom in the ring
    • C08K5/1515—Three-membered rings
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D163/00—Coating compositions based on epoxy resins; Coating compositions based on derivatives of epoxy resins
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J163/00—Adhesives based on epoxy resins; Adhesives based on derivatives of epoxy resins

Definitions

  • the present invention is related to curable epoxy resin compositions and thermosets prepared from the curable compositions or formulations.
  • thermosets with high glass transition temperatures such as 200 °C and greater
  • UV stable and weatherable thermosets are needed for the coatings industry.
  • thermosets that are highly filled with thermally conductive or low coefficient of thermal expansion (CTE) fillers are needed for the semiconductor industry.
  • epoxide compounds are used alone, or in combination with other additives to form a desired curable formulation for various enduses. Frequently these formulations need to be low viscosity. Typical epoxy resins have viscosities at or above 10 Pa-s, which result in formulations with high viscosities that are difficult to process. Usually, the epoxide compound has to be diluted with a diluent to reduce the epoxide compound's viscosity and to provide a formulation with a processable viscosity before such epoxide resin formulation can be used.
  • An epoxide compound having a low initial viscosity, for example below (0.3 Pa-s), before mixing with other additives, to prepare a curable composition or formulation would be an advantage in the industry because such an epoxide would (i) be useful in a wide range of applications, (ii) reduce manufacturing costs, and (iii) reduce the number of additives such as diluents needed for making the curable formulation processable.
  • an epoxide compound having a low volatility for example below
  • thermoset 0.000017 Pa before mixing with other additives
  • to prepare a curable composition or formulation would be an advantage in the industry because such an epoxide with low volatility would (i) prevent evaporation of the epoxide, since a high volatility epoxide can cause void formation in a thermoset; and (ii) prevent evaporation of the epoxide and consequently a change in the epoxide hardener ratio, which can cause changes in the thermomechanical and physical properties of a thermoset such as modulus, glass transition temperature (Tg), and moisture uptake.
  • Tg glass transition temperature
  • One aspect of the present invention is directed to an epoxy curable formulation having a sufficiently low viscosity and low volatility to process the formulation more easily and more efficiently into thermoset resin products for use in a wider range of various applications and enduses.
  • a curable composition includes at least one low viscosity epoxide resin compound comprising an epoxide compound having the following chemical structure:
  • R and R 2 comprises hydrogen or a hydrocarbon group having from CI to about C20 carbon atoms; with the proviso that R and R 2 are not both hydrogen.
  • a curable composition includes: (a) at least one low viscosity epoxide resin compound comprising an epoxide compound having the following chemical structure:
  • R and R 2 comprises hydrogen or a hydrocarbon group having from CI to about C20 carbon atoms; with the proviso that R and R 2 are not both hydrogen; and (b) at least one curing agent or photoinitiator.
  • the above curable composition may include optional compounds, such as at least one catalyst, depending on the end use of the curable composition.
  • Still another embodiment of the present invention is directed to a thermoset prepared from the above curable composition.
  • the low viscosity epoxide resin compound of the present invention has a low viscosity (e.g., less than about 0.3 Pa-s) compared to standard epoxy resins (e.g., less than about 10 Pa-s).
  • a low viscosity e.g., less than about 0.3 Pa-s
  • standard epoxy resins e.g., less than about 10 Pa-s.
  • One of the advantages of using the low viscosity epoxide resin compound of the present invention is that formulations using the low viscosity epoxy resin will also exhibit a lower viscosity than those formulations prepared with a standard epoxy resin.
  • Low viscosity formulations are advantageously used in end uses that require formulations with high filler loadings such as capillary underfill and composites.
  • the present invention low viscosity cycloaliphatic epoxide resin compound can be cured with a wide variety of hardeners including amines, anhydrides, cyanate esters, and phenolics.
  • the flexibility to cure the low viscosity cycloaliphatic epoxide resin compound of the present invention with amines is advantageous because many important cycloaliphatic epoxies do not readily cure with amines.
  • the curable composition of the present invention is unique and advantageous because of its combination of a cycloaliphatic resin that is UV stable and its curability with amines.
  • Still another advantage of the low viscosity composition of the present invention is that the epoxy resin used in the composition is not made using chlorine containing raw materials such as epichlorohydrin. Therefore, the resulting epoxy resin is free of chlorohydrin and chlorine impurities (i.e., "clean") and can be used in electronics applications requiring such clean epoxy resins.
  • the epoxy resins useful in the present invention are less volatile than conventional low viscosity epoxy resins.
  • another advantage of the low volatility resin is that it can be used as a reactive diluent and in formulations that must exhibit low weight loss during cure.
  • the epoxy resin composition of the present invention includes (1) a low viscosity (e.g. less than about 0.3 Pa-s) resin, (2) a clean and halogen free (e.g. less than about 100 ppm chlorine) resin, (3) a cycloaliphatic resin that imparts UV stability, (4) a resin that exhibits low volatility (e.g. less than about 0.001 mmHg at 25 °C), and (5) a resin that provides thermosets that exhibit high glass transition temperatures (for example 270 °C).
  • One broad embodiment of the present invention is directed to providing a curable resin formulation or composition including (a) at least one low viscosity liquid epoxide compound such as DVHPTO; and a compound that allows the low viscosity liquid to cure under curing conditions.
  • the curable resin composition can include (bl) at least one curing agent such as an amine, or (b2) at least one UV photoinitiator.
  • Other optional additives known to the skilled artisan can be included in the curable composition such as for example a curing catalyst and other additives for various enduse applications.
  • the low viscosity epoxide compound useful as component (a) in preparing a curable composition of the present invention may comprise, for example, a low viscosity liquid epoxy resin compound.
  • the low viscosity liquid epoxy resin compound useful in the present invention may include the epoxy compounds described in U.S.
  • a broad scope of component (a) useful in the curable composition of the present invention includes for example a compound having the following general structure:
  • R and R 2 comprises hydrogen or a hydrocarbon group having from CI to about C20 carbon atoms and can be, but is not limited to cycloaliphatic, and bicyclic groups; with the proviso that R and R 2 are not both hydrogen.
  • the above low viscosity epoxy compound may include DVHPTO, an epoxy having the structure as shown in Structure (II) as follows:
  • the low viscosity epoxy compound may have the structure as shown in Structure (III) as follows:
  • the low viscosity epoxy compound may have the structure as shown in Structure (IV) as follows:
  • a process useful for preparing the low viscosity epoxide compound described above, such as DVHPTO can include for example the process described in U.S. Provisional Patent Application Serial No. 61/718,752.
  • the low viscosity epoxy resin, such as DVHPTO, useful for the curable composition of the present invention may be produced by reacting or epoxidizing 2,4-divinylbicyclo[3.3.0]oct-6-ene) [DVHP] with at least one oxidizing agent under reaction conditions to form an epoxide.
  • the epoxide product prepared by the above process may be for example a epoxy compound having a viscosity of less than about 0.3 Pa-s and having the following general chemical structure (I):
  • Ri and/or R 2 can be, but are not limited to, a hydrocarbon group have from CI to about C20 carbon atoms including for example aliphatic, cycloaliphatic, aromatic, and bicyclic groups. Ri and R 2 can also be joined to form a cycloaliphatic or bicycloaliphatic ring. In another embodiment, the CI to C20 carbon atoms of Ri and R 2 may contain an oxirane ring attached to any one of the carbon atoms of the Ri and/or R 2 groups.
  • the process for preparing DVHPTO may include for example a two-step process, wherein as a first step includes providing a precursor DVHP; and then, as a second step, epoxidizing the DVHP under process reaction conditions to generate DVHPTO.
  • the precursor DVHP used in the first step of the above two-step process may be synthesized by any synthesis process known in the art such as for example ethenolysis of DCPD as described in U.S. Provisional Patent Application Serial No. 61/718,752.
  • the above epoxidation second step can be carried out using various epoxidation processes.
  • one useful process can include reacting DVHP with an oxidant or oxidizing agent to form the DVHPTO epoxide compound of the present invention.
  • the oxidant or oxidizing agent used in the above epoxidation second step of the above two-step process may include for example Oxone®; percarboxylic acids such as peracetic acid or meto-chloroperoxybenzoic acid; hydrogen peroxide catalyzed with acetonitrile, and mixtures thereof.
  • Oxone® percarboxylic acids such as peracetic acid or meto-chloroperoxybenzoic acid
  • hydrogen peroxide catalyzed with acetonitrile and mixtures thereof.
  • Other epoxidation processes useful in the present invention are described in U.S. Provisional Patent Application Serial No. 61/718,752.
  • the DVHPTO advantageously used in preparing the curable liquid formulation of the present invention has a low viscosity.
  • generally DVHPTO has a viscosity of less than about 0.3 Pa-s in one embodiment; from about 1.0 Pa-s to about 0.001 Pa-s in another embodiment, from about 0.5 Pa-s to about 0.01 Pa-s in still another embodiment, and from about 0.3 Pa-s to about 0.02 Pa-s in yet another embodiment, at 25 °C.
  • the viscosity of DVHPTO is much lower than standard liquid epoxy resins known in the art which typically are 10 Pa-s or higher.
  • the DVHPTO compound of the present invention is used to make a curable composition which, in turn, can be cured to form a thermoset.
  • the concentration of the liquid DVHPTO epoxy compound used in the curable composition of the present invention as the epoxy resin may range generally from about 5 weight percent (wt %) to about 99.5 wt % in one embodiment, from about 5 wt % to about 95 wt % in still another embodiment, and from about 5 wt % to about 90 wt % in yet another embodiment, based on the weight of the curable composition.
  • the curing agent, component (bl), blended with the epoxy resin compound, component (a), to prepare the curable composition may comprise, for example, any conventional curing agent known in the art useful for including in a curable
  • the curing agent (also referred to as a hardener or cross-linking agent) useful in the curable composition, may be selected from, for example, but are not limited thereto, anhydrides, carboxylic acids, amine compounds, phenolic compounds, cyanate ester compounds, or mixtures thereof.
  • Examples of curing agents useful in the present invention may include any of the co-reactive or catalytic curing materials known to be useful for curing epoxy resin based compositions.
  • co-reactive curing agents include, for example, polyamine, polyamide, polyaminoamide, dicyandiamide, polymeric thiol, polycarboxylic acid and anhydride, and any combination thereof or the like.
  • co-reactive curing agent examples include diaminodiphenylsulfone, styrene-maleic acid anhydride (SMA) copolymers; and any combination thereof.
  • SMA styrene-maleic acid anhydride
  • conventional co-reactive epoxy curing agents amines and amino or amido containing resins and phenolics are preferred.
  • amine co-reactive curing agents useful in the composition of the present invention include aromatic amines such as methylene dianiline. Also included are aliphatic amines such as xylylene diamine, aminoethanol, ethylene diamine, propylene diamine, diethylene triamine, triethylene tetramine, tetraethylene pentamine, aminated polyols such as Jeff amines (Huntsman trademark), cycloaliphatic amines such as isophorone diamine, bis-paraaminocyclohexyl methane, and
  • phenolic curing agents useful in the composition of the present invention include bisphenols of the formula HOC 6 H 4 -Z-C 6 H 4 OH where Z can be 2,2-propylidene, 1,1-ethylidene, 1,2-ethylidene, methylene, sulfone, and oxygen.
  • Other specific examples include resorcinol, hydroquinone, naphthalenediol, phenolphthalein and polyphenols (novolacs) such as condensation products of phenols and bisphenols with formaldehyde and other aldehydes.
  • anhydride curing agents useful in the composition of the present invention include maleated hydrocarbon polymers such as maleated
  • polybutadiene copolymers of maleic anhydride with styrene, polyphthalic anhydrides, cycloaliphatic anhydrides such as nadic anhydride, methyl nadic anhydride, methyl hexahydrophthalic anhydride; and mixtures thereof.
  • cyanate ester curing agents include, but are not limited to bisphenol A cyanate ester; l,l-bis(4-cyanatophenyl)ethane; novalac cyanate esters such as PrimasetTMPt-15; aromatic cyanate esters; w,3-dicyanatobenzene;
  • the amount of the curing agent used in the curable composition of the present invention may be for example, from about 5 wt % to about 95 wt % in one embodiment, from about 10 wt % to about 95 wt % in another embodiment; from about 15 wt % to about 95 wt % in still another embodiment; and from about 20 wt % to about 90 wt % curing agent in yet another embodiment.
  • the curable composition of the present invention may comprise an ultra violet light (UV) curable composition which includes for example a photoinitiator compound in the composition.
  • UV curable composition can be subjected to a source of UV light to cure the composition.
  • the UV curable composition of the present invention can include (a) at least one low viscosity liquid epoxy resin compound, such as DVHPTO; and (b) a photoinitiator to provide a UV curable composition.
  • a low viscosity liquid epoxy resin compound such as DVHPTO
  • a photoinitiator to provide a UV curable composition.
  • the photoinitiators which may be used to achieve polymerization in the present invention can include diazonium salts, iodonium salts, aryl diazonium salts, aryl iodonium salts, arylsulfonium salts, diaryliodonium salts,
  • these salts contain complex metal halide or other non-nucleophilic ions such as BF 4 -, PF 6 -, SbF 6 -, AsF 6 -, C10 4 -, CF 3 SO 3 -, (C 6 F 5 ) 4 B- and the like.
  • the photoinitiators useful in the present invention may include sulfonium salts of the formula Ar-C(0)CH 2 S+R'R"X- wherein Ar is monocyclic or bicyclic aryl or substituted aryl, such as phenyl, naphthyl, biphenyl, anthracenyl, phenanthryl, or heterocyclic such as furanyl or thiophenyl; R' and R" are the same or different and are alkyl, cycloalkyl or aromatic, and x- is a non-nucleophilic anion as described above.
  • Ar is monocyclic or bicyclic aryl or substituted aryl, such as phenyl, naphthyl, biphenyl, anthracenyl, phenanthryl, or heterocyclic such as furanyl or thiophenyl
  • R' and R" are the same or different and are alkyl, cycloalkyl or aromatic
  • x- is a
  • Suitable photoinitiator salts useful in the composition of the present invention can include commercially available photoinitiators such as PP-33 available from Asahi Denka Kogyo K. K.; FC-509 available from Minnesota Mining and Manufacturing Company; UVE 1014 available from G.E.; CP-66 and CP-77 available from Asahi Denka Kogyo K. K; SI-60L, SI-80L, SI-100L, and SI-110L available from Sanshin Chemical Industry Co., Ltd.; and CG-24-61 available from Ciba Geigy Ltd.
  • Other cationic c photoinitiators useful in the present invention may also include commercially available photoinitiators such as CPI6992 and CPI6976 available from Aceto Corp.
  • CPI6992 and CPI6976 comprise a mixed triaryl sulfonium hexafluorophosphate salt solution in propylene carbonate.
  • suitable photoinitiator salts usefuyl in the present invention may include the photoinitiator salts described in Crivello and Dietliker, in Chemistry & Technology of UV & EB Formulation for Coatings Inks & Paints, Vol. 3, 1991, page 329, the disclosure of which is hereby incorporated herein by reference.
  • the amount of photoinitiator used in the UV curable composition of the present invention may be for example, from about 0.01 wt % to about 10 wt % solids based on the weight of the epoxy compound or compounds in one embodiment, from about 0.1 wt % to about 10 wt % solids in another embodiment, and from about 0.5 wt % to about 5 wt % solids in still another embodiment.
  • one aspect of the present invention includes a UV curable composition containing the low viscosity epoxy compounds of the present invention and one or more photoinitiators for polymerization of the composition. Rapid and complete polymerization of the epoxy compounds can be achieved by irradiating the curable composition with an electron beam or x-ray dose on the order of 0.1 to 10 Mrad or ultraviolet radiation flux on the order of 10-30 mW/cm 2 . Higher energy levels are also useful, especially when higher throughput speeds are desired or thicker masses of polymer are presented.
  • Photopolymerizable compositions containing the epoxy compounds of the present invention can also contain any of the other additives customary for such uses, in the amounts thereof adequate to enable the additive to perform its desired function.
  • additives include photosensitizers, fillers, flow control agents, and the like. Examples of suitable materials for providing these functions abound in this field and are well known to those experienced in this field, and include the materials which are employed for those functions.
  • the UV curable composition can include (a) a low viscosity liquid epoxy resin compound and (b) a UV photoinitiator.
  • the coating formulation includes for example a low viscosity liquid epoxy resin compound in a concentration of from about 95 wt % to about 99.9 wt %; and a UV photoinitiator in a concentration of from about 0.01 wt % to about 5 wt %.
  • optional compounds may be added to the curable composition of the present invention depending on the end use in which the curable composition will be used.
  • the optional compounds may include for example compounds to enhance application properties (e.g. surface tension modifiers or flow aids), reliability properties (e.g. adhesion promoters), reaction rate, selectivity of the reaction, and/or lifetime.
  • Optional compounds that may be added to the curable composition of the present invention may include, for example, a cure catalyst (for example, imidazole, acid catalysts, ammonium blocked acid catalysts, quaternary amines, superacid catalysts, metal complexes) and such catalysts may be added to the formulation.
  • a cure catalyst for example, imidazole, acid catalysts, ammonium blocked acid catalysts, quaternary amines, superacid catalysts, metal complexes
  • catalysts suitable for use with the low viscosity epoxy compound of the present invention include imidazoles such as 1-methylimidazole, 2-methylimidazole, 2-phenylimidazole, 2,4-ethylmethylimidazole, tertiary amines such as triethylamine, benzyldimethylamine, dimethylaminomethyl phenol, tris(dimethylaminomethyl) phenol, acid salts of these tertiary amines; phosphines such as triphenyl phosphine; and mixtures thereof.
  • imidazoles such as 1-methylimidazole, 2-methylimidazole, 2-phenylimidazole, 2,4-ethylmethylimidazole
  • tertiary amines such as triethylamine, benzyldimethylamine, dimethylaminomethyl phenol, tris(dimethylaminomethyl) phenol, acid salts of these tertiary amines
  • Boric acid and borate derivatives such as trimethyl borate can be used in conjunction with the above catalysts to provide latency or extended pot life to the composition of the present invention. Any combination of one or more of the above compounds can also be used to facilitate the reaction of the novel epoxy resin compound with the curing agent when a curing agent is used in the composition.
  • Another optional compound useful in the present invention may include a solvent, such as for example, methyl isobutyl ketone, Dowanol® PM, cyclohexanone, toluene, methyl ethyl ketone or any combination thereof, to lower the viscosity of the formulation further than the inherent viscosity of the low viscosity epoxy compound, if desired.
  • a solvent such as for example, methyl isobutyl ketone, Dowanol® PM, cyclohexanone, toluene, methyl ethyl ketone or any combination thereof, to lower the viscosity of the formulation further than the inherent viscosity of the low viscosity epoxy compound, if desired.
  • Still another optional compound useful in the present invention may include another epoxy resin, i.e., a second epoxy compound different from the liquid epoxy resin component (a) such as for example, aromatic and aliphatic glycidyl ethers; cycloaliphatic epoxy resins; divinylarene dioxides such as divinylbenzene dioxide or any combination thereof, in addition to the liquid epoxy resin component (a) to form the epoxy matrix in the final curable formulation.
  • a second epoxy compound different from the liquid epoxy resin component (a) such as for example, aromatic and aliphatic glycidyl ethers; cycloaliphatic epoxy resins; divinylarene dioxides such as divinylbenzene dioxide or any combination thereof, in addition to the liquid epoxy resin component (a) to form the epoxy matrix in the final curable formulation.
  • Other optional compounds useful for adding to the curable composition of the present invention may depend on the end use of the curable composition and may include other resins such as a phenolic resin, other curing agents, fillers, pigments, toughening agents, flow modifiers, adhesion promoters, diluents, stabilizers, plasticizers, catalyst de- activators, flame retardants, and mixtures thereof.
  • resins such as a phenolic resin, other curing agents, fillers, pigments, toughening agents, flow modifiers, adhesion promoters, diluents, stabilizers, plasticizers, catalyst de- activators, flame retardants, and mixtures thereof.
  • fillers useful for adding to the curable composition of the present invention may include talc, clay, calcium carbonate, silica, alumina, sand, silicon carbide, boron nitride, boron carbide, aluminum nitride, and mixtures thereof.
  • fillers such as carbon, graphite, carbon fibers, silver, copper, and aluminum may also be used.
  • a lower grade of DVHPTO for example a DVHPTO containing a certain level of impurities (e.g. impurities such as diepoxides and monoepoxides) may optionally be used in addition to or as the low viscosity liquid epoxy resin compound of the present invention curable composition. While impurities found in a lower grade of DVHPTO may lower the glass transition temperature of the final composition, some enduses may withstand such lower glass transition temperatures.
  • impurities e.g. impurities such as diepoxides and monoepoxides
  • the amount of other optional components, when used in the present invention may be for example, from 0 wt % to about 95 wt % in one embodiment and from about 0.01 wt % to about 80 wt % in another embodiment.
  • the process for preparing the curable composition of the present invention includes admixing (a) at least one liquid epoxide compound of the present invention such as DVHPTO; (b) at least one curing agent such as an amine or at least one UV photoinitiator; and (c) optionally, other optional ingredients or additives as needed.
  • the preparation of the curable resin formulation of the present invention is achieved by blending, in known mixing equipment, the compound, and the curing agent, and optionally any other desirable additives.
  • Any of the above-mentioned optional additives, for example a curing catalyst may be added to the composition during the mixing or prior to the mixing to form the composition.
  • All the compounds of the curable formulation are typically mixed and dispersed at a temperature enabling the preparation of an effective curable epoxy resin composition having the desired balance of properties for a particular application.
  • the temperature during the mixing of all components may be generally from about room temperature (20 - 25 °C) or higher if necessary to enable the preparation of an effective curable epoxy resin composition having the desired balance of properties for a particular application 0 °C to about 100 °C in one embodiment, and from about 20 °C to about 50 °C in another embodiment.
  • Lower mixing temperatures help to minimize reaction of the epoxide and hardener in the composition to maximize the pot life of the composition.
  • the preparation of the curable formulation of the present invention, and/or any of the steps thereof, may be a batch or a continuous process.
  • the mixing equipment used in the process may be any vessel and ancillary equipment well known to those skilled in the art.
  • the use of the liquid epoxide compound of the present invention imparts improved properties to the curable composition and the final cured product over conventional glycidyl ether, glycidyl ester or glycidyl amine epoxy resin formulations.
  • the unique combination of low viscosity of DVHPTO in the uncured state, and high Tg of the cured product prepared from DVHPTO enables a formulator to apply new formulation strategies.
  • the ability to cure the epoxy resin of the present invention with an expanded hardener range offers the formulator significantly improved formulation latitude over other conventional types of epoxy resins such as cycloaliphatic epoxy resins.
  • the lower vapor pressure of the liquid epoxide compound of the present invention compared to other low viscosity epoxy resins results in lower weight loss during cure in the curable composition, which prevents a negative affect on the final material properties that is known to occur with high weight loss during cure.
  • the process of the present invention includes curing the curable resin composition to form a thermoset or cured composition.
  • the curable resin composition can be cured under thermal curing conditions.
  • the process of curing of the curable composition may be carried out at a predetermined temperature and for a predetermined period of time sufficient to cure the composition; and the curing conditions may be dependent on the hardeners used in the formulation.
  • the temperature for thermal cure of the formulation may be generally from about 10 °C to about 325 °C in one embodiment; from about 100 °C to about 300 °C in another embodiment; and from about 25 °C to about 270 °C in still another embodiment; and from about 80 °C to about 250 °C in another embodiment, and generally, the curing time may be chosen between about 1 minute to about 6 hours in one
  • the curable resin composition can be cured using a UV curing mechanism under UV curing conditions.
  • the curing of a curable composition of the present invention containing a UV photoinitiator may be carried out under a predetermined amount of UV light source and for a predetermined period of time sufficient to cure the composition; and the curing conditions may be dependent on the photoinitiator used in the formulation.
  • An example of a UV formulation is described above. UV curing is generally conducted at an ambient temperature of 10-35 °C, although heat may be applied (for example with infrared lamps) to finish the cure thermally.
  • the cured product (i.e. the cross-linked product made from the curable composition) of the present invention shows several improved properties over conventional epoxy cured resins.
  • the cured product of the present invention may advantageously have a high glass transition temperature (Tg).
  • the cured product of the present invention exhibits a glass transition temperature generally of between about 50 °C and about 350 °C in one embodiment, between about 80 °C and about 300 °C in another embodiment.
  • the Tg of the cured product can be measured by differential scanning calorimetry or dynamic mechanical analysis.
  • the curable composition of the present invention may be used to manufacture a cured thermoset product.
  • the curable composition may be used in applications including electronic applications such as capillary underfill formulations and electrically conductive adhesive formulations.
  • the curable composition of the present invention may be also used as clean resin or clean reactive diluent for electronic
  • the curable composition of the present invention may also be used in, but not limited to, solder masks, conductive inks, and adhesives.
  • the low viscosity epoxide resin compound of the present invention is useful as a component in a liquid coating formulation. Typical formulations and processes for such uses are described for example in Clayton A. May, "Epoxy Resins Chemistry & Technology", 2 nd Edition, Marcel Dekker, 1988, pp 735-748 and pp 758-782, incorporated herein by reference.
  • the epoxy resin is blended with a hardener such as an amine, amide, or an anhydride optionally in the presence of a catalyst, accelerator, fillers, pigments, dyes, wetting agents, surface modifiers, viscosity modifiers, and any other additives to improve the film quality and appearance.
  • the low viscosity epoxide resin compound of the present invention makes such epoxide resin particularly suitable for solvent-free formulations, but a solvent may optionally be added to the coating formulation if desired.
  • the low viscosity epoxide resin compound of the present invention can be useful for photocure (also known as UV-cure) coatings that are used for example as surface coats, solder masks, and coatings for photolithography.
  • the low viscosity epoxide resin compound of the present invention is also useful as a component in ink formulations that are either thermally cured or photocured.
  • a light-sensitive catalyst can be used for photocuring that decomposes to a strong acid when exposed to light.
  • a general description of photocure coating technology is given, for example, in the Clayton A. May reference above at pp 763-766, incorporated herein by reference.
  • the low viscosity epoxide resin compound of the present invention is useful as a component in adhesive formulations.
  • suitable formulations are given, for example, in the Clayton A. May reference above at pp 683-693, incorporated herein by reference.
  • the low viscosity epoxide resin compound of the present invention is useful for underfill adhesives for semiconductor packaging.
  • the low viscosity epoxide resin compound of the present invention is useful for electrical and electronic applications such as for example electrical potting and encapsulation and using processes such as casting, impregnation, and resin transfer molding.
  • electrical and electronic applications such as for example electrical potting and encapsulation and using processes such as casting, impregnation, and resin transfer molding.
  • processes such as casting, impregnation, and resin transfer molding.
  • a description of typical formulations and processes for such uses is given, for example, in the Clayton A. May reference above at pp 790-813, incorporated herein by reference.
  • the low viscosity epoxide resin compound of the present invention is useful for printed circuit board applications such as for example electrical laminates. It can be used in, but it' s use is not limited to applications such as high density interconnect formulations, and pre-pregs, copper clad laminates, and low dk/df formulations for servers and routers.
  • DVHPTO stands for divinylhexahydropentalene trioxide also known as 2,4-di(oxiran-2-yl)octahydropentaleno[l,2- ⁇ ]oxirene and as illustrated in Structure (I) above.
  • DVHP stands for divinyl hexahydro pentalene, also called 2,4-divinylbicyclo[3.3.0]oct-6-ene also called l,3-divinyl-l,2,3,3a,4,6a- hexahydropentalene.
  • IPDA isophoronediamine
  • PA CM 4,4'-methylenebis-cyclohexanamine
  • ECA100 refers to Epoxy Curing Agent 100.
  • ECA100 is an anhydride hardener that is commercially available from Dixie Chemical Company, Inc.; and is composed of methyltetrahydrophthalic anhydride and tetrahydrophthalic anhydride.
  • EMI-24-CN is l-(2-cyanoethyl)-2-ethyl-4(5)-methylimidazole and commercially available from PCI Synthesis.
  • UVI 6992 is a product containing approximately 55 wt % propylene carbonate and approximately 45 wt % mixed triaryl sulfonium salts; and is commercially available from Aceto Corp.
  • Xiameter® OFS-6040 is an epoxy-functionalized tri-methoxy silane commercially available from Dow Corning.
  • Jeffamine® D230 is a difunctional polyetheramine commercially available from Huntsman.
  • MP8FS Silica is a silica particles product having a mean particle size of
  • MP15EF Silica is a silica particles product having a mean particle size of 1.1 ⁇ ; both products which are commercially available from Tatsumori.
  • D.E.R. 354 is bisphenol F diglycidylether resin having an EEW of about 170;
  • D.E.R 383 is bisphenol A diglycidyl ether resin having an EEW of about
  • D.E.R. 560 is a brominated epoxy resin; all products which are commercially available from The Dow Chemical Company.
  • Epodil 749 is a reactive diluent, which is the diglycidyl ether of neopentyl
  • Epodil 750 is the diglycidyl ether of 1,4-butanediol
  • Epodil 757 is the glycidyl ether of cyclohexane dimethanol; all products of which are commercially available from Air Products.
  • EpiClon 830 LVP is high purity bisphenol F epoxy resin available from DIC
  • Kayahard AA is 4,4'-methylenebis-(2-ethylaniline) available from Nippon
  • SMA EF-40 is a styrene-maleic anhydride copolymer with a styrene:maleic anhydride ratio of approximately 4:1 and is commercially available from Cray Valley.
  • Byk®-W 996 and Byk A530 are both wetting and dispersing agent available from Byk Chemie.
  • Tg was obtained via Dynamic Mechanical Thermal Analysis.
  • a three-point bend test was used to collect tan delta data. Samples were approximately 12.5 mm wide and 12 mm long. The samples were then measured with a caliper, placed on the 10 mm 3-Point Bend Fixture of the TA Instruments RSA III Rheometer and tested in a closed oven with a constant nitrogen flow. A dynamic temperature ramp was performed: samples were measured with an oscillatory test (1 Hz) along a temperature ramp (5 °C/minute) starting from room temperature and stopping at 300°C. Tg was reported as peak tan delta.
  • Viscosities were collected using an AR2000EX stress controlled rheometer
  • a glass slide flow test vehicle is constructed by placing 2 pieces of 50 ⁇ thick tape onto opposite sides of a glass slide. A cover slip is placed on top of the tape to create a 50 ⁇ gap and the cover slip is taped in place. Underfill is applied along one side of the cover slip and the time it takes to fill the area under the glass cover slip is recorded as the flow time.
  • a 40 mg (+/- 1 mg) sample was placed in a TGA pan and ramped to 150 °C at a rate of 10 °C/minute and held isothermally at that temperature for 20 minutes.
  • T g glass transition temperatures
  • thermosets were prepared with various concentrations of the components described in Table I as follows: The compounds in each of the examples described in Table I were thoroughly mixed together to form a resin mixture. Each one of the resin mixtures of Table I were separately coated onto a 10 cm by 10 cm piece of interwoven glass cloth. Then the resultant coated cloth was cured in an oven at 100 °C for 1 hour, followed by a post-cure at 220 °C for 2 hours.
  • DVHPTO and UVI 6992 catalyst were combined in accordance with the weights shown in Table III; and then the mixture was applied to Bonderite steel panels as a film having a thickness of 12 microns.
  • the panels were UV processed using a 240 W/cm mercury bulb to form a coating.
  • the formulations cured to give coated panels.
  • DVHPTO, silica, and carbon black were added to a polyethylene FlackTekTM speed mixing container and mixed using a FlackTekTM DAC150 speed mixer for 30 seconds (s) at 2500 revolutions per minute (rpm).
  • Xiameter® OFS-6040 silane (1.1 wt % on silica) was added to the FlackTekTM DAC150 speed mixer; and the resulting sample was mixed for 30 s at 2500 rpm.
  • Jeffamine® D230 was added to the sample and then the sample was further mixed for 30 s at 2500 rpm.
  • the sample was roll-milled using a 3 roll mill.
  • the weight of IPDA was re-calculated to account for material losses during roll milling and then the IPDA was added to the sample.
  • the sample was mixed again at 2500 rpm for 30 s and then degassed for 15 minutes under vacuum in a bell jar. The weight percent of each component is described in Table IV. TABLE IV
  • EpiClon EXA 830-LVP and silica were added to a polyethylene FlackTekTM speed mixing container and mixed using a FlackTekTM DAC150 speed mixer for 30 s at 2500 rpm.
  • Xiameter® OFS-6040 silane (1.1 wt % on silica) was added and the sample was mixed for 30 s at 2500 rpm.
  • Byk®-W 996 was added and the sample mixed for 30 s at 2500 rpm.
  • Byk® A530 was added and the sample mixed for 30 s at 2500 rpm.
  • Kayahard AA was then added and the sample mixed for 30 x at 2500 rpm. The sample was then degassed for 15 minutes under vacuum in a bell jar. The weight percent of each component is listed in Table V.
  • DVHPTO was added to D.E.R. 383 at various weight percents as described in Table VII. DVHPTO was shown to decrease the viscosity of the epoxy resin D.E.R. 383 as shown in Table VII.
  • 1-methylimidazole as a catalyst and DVHPTO as a reactive diluent was prepared.
  • the reagents in Table VIII were added to a polyethylene FlackTekTM speed mixing container and mixed for 30 s at 2500 rpm to prepare a homogeneous solution.
  • 1-methylimidazole 0.4 g were added to a polyethylene FlackTekTM speed mixing container and mixed for 30 s at 2500 rpm to prepare a homogeneous solution.
  • D.E.R. 560 in (60% in MEK), SMA-EF-40 (60% in MEK), DVHPTO, and 2-MI (20% in Dowanol PM) were weighed into a 200 mL jar and placed on a shaker until a homogeneous mixture was obtained.
  • the weights used for the formulation are shown in Table XI. An epoxy/hardener ratio of 1.0 was used.
  • D.E.R. 560 in (60% in MEK), SMA-EF-40 (60% in MEK), and 2-MI (20% in Dowanol PM) were weighed into a 200 mL jar and placed on a shaker until a homogeneous mixture was obtained.
  • the weights used for the formulation are shown in Table XII.
  • Example 9 The above formulations from Example 9 and Comparative Example L were gelled at 171 °C on a hot plate. The gelled samples were then post-cured for 2 hours at 200 °C in an oven. The cured samples were analyzed for Tg and the resulting data is shown in Table XIII. DVHPTO was shown to increase Tg. Table XIII

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Abstract

La présente invention concerne une composition durcissable contenant (a) au moins un composé de type résine époxy de faible viscosité de formule chimique suivante : (I) dans laquelle R1 et R2 représentent de l'hydrogène ou un groupe hydrocarbure comportant de 1 à 20 atomes de carbone, sous réserve que R1 et R2 ne représentent pas tous deux de l'hydrogène, et (b) au moins un agent durcisseur ou un photoinitiateur UV. L'invention concerne également une résine thermodurcissable préparée à partir de ladite composition durcissable.
PCT/US2013/066738 2012-10-26 2013-10-25 Compositions durcissables contenant des composés époxy à base de 1,3-dioxiranylcyclopentane et résines thermodurcissables préparées à partir de celles-ci WO2014066718A1 (fr)

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KR1020157010411A KR20150079627A (ko) 2012-10-26 2013-10-25 1,3-디옥시라닐시클로펜탄 에폭시드 화합물을 포함하는 경화성 조성물 및 그로부터 제조된 열경화성 물질
EP13786399.9A EP2912028A1 (fr) 2012-10-26 2013-10-25 Compositions durcissables contenant des composés époxy à base de 1,3-dioxiranylcyclopentane et résines thermodurcissables préparées à partir de celles-ci
JP2015539825A JP2015535308A (ja) 2012-10-26 2013-10-25 １，３−ジオキシラニルシクロペンタン・エポキシド化合物を含む硬化性組成物及びそれから調製される熱硬化性物質
CN201380054146.8A CN104736528A (zh) 2012-10-26 2013-10-25 包含1,3-二环氧乙烷基环戊烷环氧化合物的可固化组合物和由其制备的热固性物
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US9631065B2 (en) * 2013-03-12 2017-04-25 Intel Corporation Methods of forming wafer level underfill materials and structures formed thereby
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CN113348193B (zh) * 2019-02-01 2023-08-18 富士胶片株式会社 导热材料形成用组合物、导热材料

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GB1185137A (en) * 1968-01-24 1970-03-18 Shell Int Research Novel Epoxides and Cured Polymers obtained therefrom
WO2011114935A1 (fr) * 2010-03-18 2011-09-22 新日鐵化学株式会社 Composition de résine époxyde et substance durcie
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CN104736528A (zh) 2012-10-26 2015-06-24 陶氏环球技术有限公司 包含1,3-二环氧乙烷基环戊烷环氧化合物的可固化组合物和由其制备的热固性物

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GB1185137A (en) * 1968-01-24 1970-03-18 Shell Int Research Novel Epoxides and Cured Polymers obtained therefrom
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